Arc Machines 501 Operation Manual Download

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10500 Orbital Way

Pacoima, California 91331 U.S.A.

MODEL 501 POWER SUPPLY

OPERATION MANUAL

Document No. 740099

Rev.

Summary of Contents for 501

Page 1: ...10500 Orbital Way Pacoima California 91331 U S A MODEL 501 POWER SUPPLY OPERATION MANUAL Document No 740099 Rev ...

Page 2: ... du Lavasson 2 CH 1196 Gland Switzerland Tel 41 22 995 00 51 Fax 41 22 995 00 59 sales arcmachines ch GERMAN OFFICE Arc Machines GmbH Markelsbach 2 D 53804 Much Germany Tel 49 2245 91680 Fax 49 2245 916868 sales arcmachines de UK OFFICE Arc Machines UK Limited 10 Ashurst Court London Road Wheatley Oxford OX331ER England Tel 44 1865 872121 Fax 44 1865 876909 sales arcmachines co uk ...

Page 3: ...n at higher welding speeds than cold wire systems When used with GTA welding sys tems such as Arc Machines Model 415 Microprocessor based power supply high quality weld deposits characteristic of the gas tungsten arc process are obtained The Model 501 uses AC current to preheat the wire True values of current and voltage allow welding engineers to precisely calculate energy input in Joules per inc...

Page 4: ...ions M 501 Do s and Don ts Warnings MODEL 501 SPECIFICATIONS POWER SUPPLY OPERATION FUNCTIONS Wire Feeder System Configurations WELDING JOINT PREPARATION FOR HOT WIRE WELDING ELECTRICAL DRAWINGS GRAPHICAL SYMBOLS INDEX INDEX 1 2 3 4 5 6 7 8 9 MODEL 501 Hotwire Power Supply OPERATION MANUAL General Guidelines for Welding with Hot Wire ...

Page 5: ...ge The hot wire GTAW TIG welding process differs from the cold wire process in that the filler wire is electrically pre heated to near melting temperature before entering the weld pool This prevents the wire from chilling the weld pool and allows the filler metal to flow out across the weld puddle resulting in a smooth attractive weld bead Since nearly all of the full energy of the welding arc is ...

Page 6: ...ded by these measurements make it possible to duplicate production conditions from one set up to the next with excellent repeatability of process Applications The Model 501 can be operated by an Arc Machines Model 415 Power Supply an external weld process controller or program or can stand alone and be operated from its own pendant The hot wire GTAW process produces a very clean weld with a very l...

Page 7: ...us the hot wire GTAW process is particularly applicable to 300 series stainless steel as well as to engineered materials such as duplex stainless steels or high nickel alloys where the metallurgical properties of the base metal may be adversely affected by welding unless high quality welding procedures are employed The proper use of the GTAW process with the addition of hot wire can optimize the c...

Page 8: ...SP Power Supply as a controller The Model 415 is Windows based with built in digital data acquisition and multi servo control capabilities It is a very capable power supply that is easy to operate The heart of its flexibility is the emphasis on user definability Almost all function ranges and modes can be defined by the user to exactly match the unique Model 2 configuration being used The closed l...

Page 9: ...rts operating at very high temperatures represent a burn hazard Operators must wear proper protective clothing including eye protection when operating welding equipment This chapter of the manual explains and illustrates common dangers and precautions to take while oper ating welding equipment THE ELECTRODE SHOULD ALWAYS BE CONSIDERED A POSSIBLE SHOCK HAZARD and touching it or internal circuits co...

Page 10: ...r an aborted or bad arc attempt How ever these circuits take a few sec onds or could fail for Safe Use of Welding Hot Wire Equipment Caution Only experienced personnel familiar with the operation and safe practice of welding equipment should install or use this equipment DO S 1 Do disconnect input power before servicing equipment 2 Do properly install and ground this equipment 3 Do VERIFY correct ...

Page 11: ... a feeling of sand or grit in the eye blurred vision intense pain tearing burning and headache The arc can reflect off surrounding materials and burn co workers who work nearby About half of welder s flash injuries occur in co workers who are not welding Welders and cutters who continually work around ultra violet radiation without proper protection can suffer permanent eye damage 10 Do wear weldi...

Page 12: ...en using the Model 501 3 Don t attempt to weld without PROPER FACING AND CLEANING OF THE MATERIAL to be welded 4 Don t route the cables where they will be SUBJECT TO DAMAGE from traffic or equipment 5 Don t C on cables This will result in DAMAGE TO THE EQUIPMENT 6 Don t add oil or grease to the wire feed mechanism 7 Don t increase GAS FLOW RATE CFH to GTAW torch beyond levels that could result in ...

Page 13: ...inst such interference WARNING Magnetic fields from High Currents can affect pace makers PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR WARNING Disconnect the input power to the machine before opening or servicing Discharge all circuits that store high voltage such as capacitor packs Only QUALIFIED service personnel should open this equipment Safety Precautions This section concerning sa...

Page 14: ...nts and the welding equipment Both can cause severe burns Do not touch recently welded components Avoid touching internal components of the welding system soon after use Avoid touching torch components and welding fixtures soon after welding WARNING The welding arc emits ultra violet UV radiation and the molten weld gives off infra red Both can burn eyes and skin if unprotected Suitable eye and sk...

Page 15: ...dates of training classes and other training information WARNING Some systems such as the M 501 Power Supply are intended solely for indoor use and must be kept dry Before operat ing storing or handling always make sure that the M 501 M 501 Operator Pendant weld heads and cables are not exposed to rain or standing water SYSTEM COMPONENTS ARE NOT WATER PROOF WARNING Keep hands and fingers clear fro...

Page 16: ...Ø Output CC Mode 250 Amps true RMS AC 3 maximum CV Mode 0 10 Volts true RMS AC 3 maximum Open Circuit Voltage 16 VAC Loop Response 1 2 Seconds Duty Cycle 100 Weight 135 lbs 61 5 kg Dimensions 23 x 19 x 9 5 inches 585 x 485 x 240 mm Remote Control Interface External Controller Voltage Current Level CC Mode 0 025 Volts Amp input 2 50 VDC 250 A RMS AC Output CV Mode 0 100 Volts Volt input 1 00 VDC 10...

Page 17: ... 7 9 1 6 AB33CC D 6 J 8 E I F G H Model 501 Remote Operator Pendant An AMI Wirefeed head and wire feed torch may be used on the Model 2 in conjunction with the Model 501 Power Supply Model 501 Remote Operator Pendant ...

Page 18: ... weld head definition for the GTAW head being used with the 501 must reside in the Model 415 Water Cooling Due to the high amperage typically used with hot wire applications water cooling of the GTAW torch is highly recom mended Wire Feeder The Model 501 does not control the wire feeder it only sup plies the current to heat the wire When the Model 501 is used as a stand M 501 remote connector conn...

Page 19: ...sible System Configurations using the Model 501 Hotwire Power Supply The Model 501 is flexible and can be configured in a variety of ways depending on customer application and requirements Some examples are given here Consult factory for any special cable requirements Model 501 used as a Stand Alone Unit Set Up of Model 501 as a stand alone unit controlled by the 501 Remote Programming Pendant The...

Page 20: ...S2 Operation of the Model 501 Hot Wire Power Supply by an External Controller The controller plugs in to the remote operation bypass switch S2 The controller con trols the Model 501 hot wire current a separate wire feeder and the GTAW power supply Set Up of Model 501 Power Supply used in conjunction with an Arc Machines Model 415 GTAW power source Wire feed and hot wire current controlled by Model...

Page 21: ... analog ground F 5V meter Power output Not insulated from analog ground G Voltage meter signal Not insulated from analog ground H Current meter signal Not insulated from analog ground J System enable input Insulated from analog ground K Command signal input Insulated from analog ground L Command signal input I Insulated from analog ground M System analog ground N CP CC control Not insulated from a...

Page 22: ...ge wire diameter and wire feed speed have already been established When the Arc Machines hot wire system is added to an existing system some changes are necessary The hot wire guide tube should be insulated and aimed at the trailing edge of the weld puddle The wire entry angle of 45 to 50 degrees is typically steeper than is common with cold wire Because of the wide variation of applications only ...

Page 23: ...wire Ide ally there should be no depression in the puddle Wire melts as it enters the puddle and rolls in smoothly If a depression forms in the puddle or the wire hits the bottom of the puddle then adjust the hot wire power or wire feed speed until the puddle smooths out If the wire is popping in space and burning back this indicates there is too much hot wire power or not enough wire feed Good wi...

Page 24: ...ch the weldment is rotated and the electrode remains stationary Joint preparations are considerably more critical for automatic welding applications than for manual applications Since welding equipment does not sense or react to changes in the preparation the preparation and fit up must be precise in order to realize the repeatability and consistency expected of automatic machine or orbital weldin...

Page 25: ... 0 1 234 5 67 8 7 9 1 6 AB33CC D 6 K 8 E I F G H Hot Wire GTA welding of pipe is most efficient when the pipe can be rotated and the electrode remains in place ...

Page 26: ...ngs The following documents are attached 1 501 Hotwire PS Basic Assembly Drawing 25E010101 2 501 Hotwire PS Remote Pendant Assembly Drawing 25E010102 3 501 Hotwire PS Wiring Diagram 47E010101 4 501 Hotwire Remote Control Wiring Diagram 47E010102 5 501 Hotwire PS Wiring Diagram CE 47E010105 ...

Page 27: ... the Earth Ground Connection IEC 417 5017 5 Work Connection To Signify a Work Piece Connection ISO 7000 0453 6 Electrode Nega tive To Signify Electrode Negative Connection or Switch Position ANSI NEMA 7 Electrode To Signify an Electrode ANSI NEMA 8 Ventilating and Air Circulating Fan To Signify a Ventilating Fan or Air Circulating ISO 7000 0089 9 Protective Boots over Cable Connector To Signify Se...

Page 28: ...ack Welds with a GTAW Torch ISO 7000 0465 17 Orbital GTAW To Signify the Orbital GTAW Process ISO 7000 0465 AMI 18 V Input Voltage Power To Signify Input Voltage Power IEC 417 5034 ANSI NEMA 19 Pipestand To Signify use of a Pipestand AMI 20 Stop of Action To Signify the Stop of Action Function or Con trol ANSI NEMA 21 Process Cycle To Signify One Com plete Process Cycle Weld Sequence ANSI NEMA 22 ...

Page 29: ...ing of Air by Gas ISO 7000 0474 29 Remote Signifies Remote Opera tion or Control ANSI NEMA 30 Start To Signify the Start of Action Function or Con trol ANSI NEMA 31 Pushbutton To Signify a Pushbutton Switch used to Start or Stop a Function ANSI NEMA 32 Panel LOCAL To Signify Panel Local Function or Switch such as a Switch to Change Between a Local Control and a Remote Control ANSI NEMA 33 ON OFF S...

Page 30: ...ctrode Travel Speed To Signify Travel Speed of the Electrode or Torch SAE ANSI NEMA AMI 43 Direction of electrode travel To Signify Direction of Electrode Travel ANSI NEMA AMI 44 Electrode Travel Start Delay To Signify the Time after Arc Start that the Elec trode Begins to Move ANSI NEMA AMI 45 Electrode Travel Stop Delay To Signify the Time between the end of the last Level and travel Stop ANSI N...

Page 31: ...1 54 V Voltage control To Signify Voltage or Voltage Control S1 55 HF High Frequency S1 56 HZ HERTZ To Signify Cycles per Second S1 57 5G 5G Welding Position To Signify Pipe Horizon tal Position 58 Wire Feed To Signify a Wirefeed Unit or Wirefeed Func tion ANSI NEMA 59 Wirefeed Manual Advance Cold Jog Inch Towards Workpiece ANSI NEMA 60 Wirefeed Retract Manual Cold Jog Inch Away From Workpiece ANS...

Page 32: ...7 Wire Manipulator Position To Signify the Position or Position Control of the Wire Manipulator ANSI NEMA AMI 68 Diameter Signifies diameter such as the diameter of wire or electrode or pipe ANSI Y14 5 M 1982 69 Leading Wire Entry To Signify Wire Entry into the Leading Edge of the Weld Pool ANSI NEMA AMI 70 Trailing Wire Entry To Signify Wire Entry into the Trailing Edge of the Weld Pool ANSI NEMA...

Page 33: ... Drawing Page 2 7 2 Hotwire Remote Control Assembly Drawing 7 5 Remote Control Wiring Diagram 7 6 501 Hotwire Remote Control Assembly Draw ing 7 3 501 Hotwire Wiring Diagram 7 4 duplex stainless steels 1 3 E electric shock 2 1 external controller 4 3 external voltage sensor 4 1 external wire feed controller 4 2 eye protection 2 1 F facing 2 4 fit up 6 1 G gas cylinders 2 4 gas flow rate 2 4 ground...

Page 34: ...ARD 2 1 stand alone unit 4 1 4 2 stick out 5 2 System Configu rations 4 2 T tanks and vessels 1 3 TEST mode 2 1 trailing edge 5 1 true RMS 1 2 true sine wave 1 2 V voltage 1 1 5 1 open circuit voltage 2 1 voltage feedback input 5 1 W Warnings Disconnect the input power 2 5 Do not weld in enclosed areas 2 7 emission of toxic fumes 2 6 energized electrical parts 2 5 factory training is essential 2 7...

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